US6260893B1 - Fascia for a motor vehicle having reduced wall thickness - Google Patents

Fascia for a motor vehicle having reduced wall thickness Download PDF

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Publication number
US6260893B1
US6260893B1 US09/701,039 US70103900A US6260893B1 US 6260893 B1 US6260893 B1 US 6260893B1 US 70103900 A US70103900 A US 70103900A US 6260893 B1 US6260893 B1 US 6260893B1
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fascia
automobile
accordance
reinforcement particles
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US09/701,039
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English (en)
Inventor
Phillip S. Wilson
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Magna International of America Inc
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Magna International of America Inc
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Assigned to MAGNA INTERNATIONAL OF AMERICA, INC. reassignment MAGNA INTERNATIONAL OF AMERICA, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: WILSON, PHILLIP S.
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/03—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by material, e.g. composite
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/48—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects combined with, or convertible into, other devices or objects, e.g. bumpers combined with road brushes, bumpers convertible into beds

Definitions

  • This invention relates to a fascia for a motor vehicle.
  • this invention relates to a fascia having reduced wall thickness.
  • Fascia for motor vehicles typically require superior impact characteristics. More particularly, these parts must be engineered to be sufficiently flexible and ductile so as to flex and return to their original shape without cracking in the event of predetermined front or rear vehicle impact. Thus, vehicle fascia typically must have a sufficiently high modulus, and must be sufficiently ductile to withstand standard impact tests.
  • Fascia are generally molded from a polyolefin material which is subsequently painted to match the other “Class A” finish exterior metal body components. It is easy to damage the pre-painted molded polyolefin parts during handling in the production facilities. This is particularly true during the frequent handling, which typically occurs between the molding operation and the paint ovens. The surface damage may not be noticed until the parts are painted with the typical high gloss exterior coatings. It is not possible to recycle the molded parts back into the molding process once they have been painted, and significant value is lost with each scrap part.
  • fascia With respect to motor vehicle fascia, it is desirable to provide a part having high impact resistant characteristics. For these applications, the dimensional stability is of lesser importance. Thus. for example, fascia can be more flexible (lower modulus) and have a higher coefficient of expansion than other body parts, such as outer door panels which are bounded on more than one side by other vehicle parts. In order to maintain the impact resistance, fascia are typically devoid of any substantial reinforcement. Because the fascia is not reinforced to any significant extent, they must be made thicker to provide the requisite dimensional stability. As the thickness of the fascia increases, more material costs are incurred. and the weight of the part is also increased. Heretofore, the thinnest fascia having sufficient dimensional stability so as to be commercially acceptable has had an average wall thickness of about 2.4 mm.
  • a fascia for an automobile comprising a structure extending horizontally and vertically across an entire front end or rear end of the automobile, the structure having an average wall thickness of less than about 2.2 mm.
  • the structure is formed from at least one polyolefin material and reinforcement particles dispersed within the at least one polyolefin material.
  • the reinforcement particles comprise less than 15% of a total volume of the structure. At least 40% of the reinforcement particles have a thickness of less than about 50 nanometers.
  • a decorative coating layer having a least one coloring agent is disposed on the rigid structure.
  • At least 50% of the reinforcement particles have a thickness of less than about 20 nanometers. It is also preferred for at least 90% of the reinforcement particles have a thickness of less than about 10 nanometers. It is also preferred for at least 99% of the reinforcement particles have a thickness of less than about 30 nanometers.
  • FIG. 1 is a front perspective view of a front end fascia for a motor vehicle having reduced wall thickness in accordance with the present invention
  • FIG. 2 is a cross sectional view taken across the line 2 — 2 in FIG. 1 .
  • the modulus of the fascia material can be greatly increased.
  • the wall thickness can be reduced while maintaining the same required impact resistant characteristics noted above.
  • the modulus of the fascia material can be increased to between about 200,000 to about 500,000 PSI, and the average wall thickness for the fascia can preferably be reduced to below 2.2 mm while maintaining the same impact resistant characteristics. More preferably. the modulus of the fascia material is between about 250,000 to 450,000 PSI and the average wall thickness for the fascia can be reduced to below 2.0 mm.
  • the thickness of the fascia in accordance with the invention is represented by reference character “t” in FIG. 2 .
  • the minimum average wall thickness for the fascia is greater than 1.4 mm, as wall thicknesses below this level do not provide adequate stiffness while retaining low temperature impact resistance.
  • the accuracy of the average wall thickness measurement is generally within about +/ ⁇ 0.2 mm.
  • the automobile fascia manufactured in accordance with the present invention comprises a composite material of a polymer having dispersed therein reinforcement fillers in the form of very small mineral reinforcement particles.
  • the reinforcement filler particles also referred to as “nanoparticles” due to the magnitude of their dimensions, each comprise one or more generally flat platelets.
  • Each platelet has a thickness of between 0.7-1.2 nanometers. Generally, the average platelet thickness is approximately 1 nanometer thick.
  • the aspect ratio (which is the largest dimension divided by the thickness) for each particle is about 50 to about 300.
  • the platelet particles or nanoparticles are derivable from larger layered mineral particles.
  • Any layered mineral capable of being intercalated may be employed in the present invention.
  • Layered silicate minerals are preferred.
  • the layered silicate minerals that may be employed include natural and artificial minerals.
  • Non-limiting examples of more preferred minerals include montmorillonite, vermiculite, hectorite, saponite, hydrotalcites, kanemite, sodium octosilicate, magadiite, and kenyaite.
  • Mixed Mg and Al hydroxides may also be used.
  • the most preferred minerals is montmorillonite.
  • swellable layered minerals such as montmorillonite and saponite are known to intercalate water to expand the inter layer distance of the layered mineral, thereby facilitating exfoliation and dispersion of the layers uniformly in water. Dispersion of layers in water is aided by mixing with high shear.
  • the mineral particles may also be exfoliated by a shearing process in which the mineral particles are impregnated with water, then frozen, and then dried. The freeze dried particles are then mixed into molten polymeric material and subjected to a high sheer mixing operation so as to peel individual platelets from multi-platelet particles and thereby reduce the particle sizes to the desired range.
  • the composites of the present invention are prepared by combining the platelet mineral with the desired polymer in the desired ratios.
  • the components can be blended by general techniques known to those skilled in the art. For example, the components can be blended and then melted in mixers or extruders.
  • the polymer used for the purposes of the present invention is a polyolefin or a blend of polyolefins.
  • the preferred polyolefin is at least one member selected from the group consisting of polypropylene, ethylene-propylene copolymers, thermoplastic olefins (TPOs), and thermoplastic polyolefin elastomers (TPEs).
  • the exfoliation of layered mineral particles into constituent layers need not be complete in order to achieve the objects of the present invention.
  • the present invention contemplates that at least 40% of the particles should be less than about 50 nanometers in thickness and. thus, at least 40% of the particles should be less than about 50 platelets stacked upon one another in the thickness direction. More preferably, at least 50% of the particles should have a thickness of less than 10 nanometers. Even more preferably, at least 70% of the particles should have a thickness of less than 5 nanometers. It is most preferable to have as many particles as possible to be as small as possible, ideally including only a single platelet.
  • At least 50% of the particles should be less than about 20 nanometers in thickness, and at least 99% of the particles should be less than about 30 nanometers in thickness.
  • the preferred aspect ratio (which is the largest dimension divided by the thickness) for each particle is about 50 to about 300. At least 80% of the particles should be within this range. If too many particles have an aspect ratio above 300, the material becomes too viscous for forming parts in an effective and efficient manner. If too many particles have an aspect ratio of smaller than 50, the particle reinforcements will not provide the desired reinforcement characteristics. More preferably, the aspect ratio for each particle is between 100-200. Most preferably, at least 90% of the particles have an aspect ratio within the 100-200 range.
  • each of the parts to be manufactured should contain less than 15% by volume of the reinforcement particles of the type contemplated herein.
  • the balance of the part is to comprise an appropriate polyolefin material and suitable additives. If greater than 15% by volume of reinforcement filler is used, the viscosity of the composition becomes too high and thus difficult to mold.
  • the modulus of the fascia can be increased without losing impact resistance. Because the modulus is increased, the fascia can be made thinner than what was otherwise possible. Conventionally, fascia materials for automobiles must have sufficient flexibility, and thus a sufficiently low modulus to withstand various standard automotive impact tests. For example, an automotive fascia must withstand a typical dart (puncture type) impact test wherein the fascia will not crack or permanently deform upon impact of at least 200 inch pounds force at a temperature of ⁇ 30° C. or lower.
  • the fascia In a conventional IZOD impact test, it is desirable for the fascia to withstand at least 10 ft pounds/inch at room temperature and at least 5ft pounds/inch at ⁇ 30° C. In order to withstand cracking at such force levels, the modulus for the fascia is typically between about 70,000 to about 150,000 pounds per square inch. (PSI). With this modulus, the thinnest fascia known has had an average wall thickness of about 2.4 mm.
  • PSI pounds per square inch
  • the modulus of the fascia material can be greatly increased, the wall thickness can be reduced while maintaining the same required impact resistant characteristics noted above. More particularly, with the loadings of exfoliated platelets discussed above, the modulus of the fascia material can be increased to between about 200,000 to about 500,000 PSI, and the average wall thickness for the fascia can preferably be reduced to below 2.2 mm while maintaining the same impact resistant characteristics. More preferably, the modulus of the fascia material is between about 250,000 to 450,000 PSI and the average wall thickness for the fascia can be reduced to below 2.0 mm. Again, the accuracy of the average wall thickness measurement techniques is within about +/ ⁇ 0.2 mm.
  • the coefficient of linear thermal expansion can be reduced to less than 40 ⁇ 10-6 inches of expansion per inch of material per degree Fahrenheit (IN/IN)/° F., which is less than 60% of what was previously achievable for motor vehicle fascia that meet the required impact tests.
  • the surface toughness of the fascia can be improved.
  • the improved surface toughness provided by the nanoparticles greatly reduces handling damage and part scrap. It also eliminates the need for the extra packaging and protective materials and the labor involved.
  • nanoparticles can provide the mechanical, thermal, and dimensional property enhancements, which are typically obtained by adding 20-50% by weight of glass fibers or mineral fillers or combinations thereof to polymers. However, only a few percent of nanoparticles are required to obtain these property enhancements.
  • these relatively flexible panels prefferably have reinforcement particles of the type described herein comprising about 2-8% of the total volume of the panel, with the balance comprising the polyolefin substrate. It is even more preferable for these exterior panels to have reinforcement particles of the type contemplated herein comprising about 3%-5% of the total volume of the panel.
  • the decorative coating layer having a least one coloring agent discussed herein may comprise any suitable paint used in the automotive industry.
US09/701,039 1998-05-22 1999-05-20 Fascia for a motor vehicle having reduced wall thickness Expired - Fee Related US6260893B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US09/701,039 US6260893B1 (en) 1998-05-22 1999-05-20 Fascia for a motor vehicle having reduced wall thickness

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US8661598P 1998-05-22 1998-05-22
US09/701,039 US6260893B1 (en) 1998-05-22 1999-05-20 Fascia for a motor vehicle having reduced wall thickness
PCT/US1999/011195 WO1999061287A1 (fr) 1998-05-22 1999-05-20 Carenage frontal a faible epaisseur de paroi destine a un vehicule motorise

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US (1) US6260893B1 (fr)
EP (1) EP1077837A4 (fr)
AU (1) AU4091099A (fr)
CA (1) CA2332874C (fr)
WO (1) WO1999061287A1 (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6736434B2 (en) * 2000-03-22 2004-05-18 Meridian Automotive Systems, Inc. Vehicle and bumper assembly therefor having an integral fascia and energy absorber, and method for making the same
US20050280268A1 (en) * 2004-06-03 2005-12-22 Andreas Dehn Motor vehicle front with a cover in the center of the spoiler area for improved pedestrian protection in a collision
US6988305B1 (en) * 1999-12-17 2006-01-24 Magna International Of America, Inc. Method and apparatus for blow molding large reinforced plastic parts
US7258395B2 (en) 2003-01-24 2007-08-21 Club Car, Inc. Composite body for a golf car and utility vehicle
US11050383B2 (en) 2019-05-21 2021-06-29 Nextracker Inc Radial cam helix with 0 degree stow for solar tracker
US11159120B2 (en) 2018-03-23 2021-10-26 Nextracker Inc. Multiple actuator system for solar tracker
US11387771B2 (en) 2018-06-07 2022-07-12 Nextracker Llc Helical actuator system for solar tracker

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2358534C (fr) * 1998-12-21 2009-02-17 Magna International Of America, Inc. Composite en mousse structuree comprenant des nanoparticules de renforcement et procede de fabrication dudit composite
US6977115B1 (en) 1998-12-21 2005-12-20 Magna International Of America, Inc. Low pressure compression molded parts having nano-particle reinforced protrusions and method of making the same
WO2000037241A1 (fr) * 1998-12-21 2000-06-29 Magna International Of America, Inc. Procede de production de pieces moulees par rotation comprenant des nanoparticules de renforcement
WO2000037243A1 (fr) * 1998-12-21 2000-06-29 Magna International Of America, Inc. Pieces moulees par compression basse pression presentant des protuberances renforcees par des nanoparticules et procede de fabrication desdites pieces

Citations (3)

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US5071500A (en) 1987-06-23 1991-12-10 Honda Giken Kogyo Kabushiki Kaisha Method of and apparatus for fusing resin members such as bumper beam and bumper face of automobile bumper
US5609374A (en) 1992-11-02 1997-03-11 Honda Giken Kogyo Kabushiki Kaisha Automobile bumper
US5711562A (en) 1995-08-24 1998-01-27 Aisin Seiki Kabushiki Kaisha Bumper assembly for vehicles

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US5071500A (en) 1987-06-23 1991-12-10 Honda Giken Kogyo Kabushiki Kaisha Method of and apparatus for fusing resin members such as bumper beam and bumper face of automobile bumper
US5609374A (en) 1992-11-02 1997-03-11 Honda Giken Kogyo Kabushiki Kaisha Automobile bumper
US5711562A (en) 1995-08-24 1998-01-27 Aisin Seiki Kabushiki Kaisha Bumper assembly for vehicles

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6988305B1 (en) * 1999-12-17 2006-01-24 Magna International Of America, Inc. Method and apparatus for blow molding large reinforced plastic parts
US6736434B2 (en) * 2000-03-22 2004-05-18 Meridian Automotive Systems, Inc. Vehicle and bumper assembly therefor having an integral fascia and energy absorber, and method for making the same
US7258395B2 (en) 2003-01-24 2007-08-21 Club Car, Inc. Composite body for a golf car and utility vehicle
US20070289792A1 (en) * 2003-01-24 2007-12-20 Club Car, Inc. Composite body for a golf car and utility vehicle
US20050280268A1 (en) * 2004-06-03 2005-12-22 Andreas Dehn Motor vehicle front with a cover in the center of the spoiler area for improved pedestrian protection in a collision
US11159120B2 (en) 2018-03-23 2021-10-26 Nextracker Inc. Multiple actuator system for solar tracker
US11283395B2 (en) 2018-03-23 2022-03-22 Nextracker Inc. Multiple actuator system for solar tracker
US11711051B2 (en) 2018-03-23 2023-07-25 Nextracker Llc Multiple actuator system for solar tracker
US11387771B2 (en) 2018-06-07 2022-07-12 Nextracker Llc Helical actuator system for solar tracker
US11050383B2 (en) 2019-05-21 2021-06-29 Nextracker Inc Radial cam helix with 0 degree stow for solar tracker
US11705859B2 (en) 2019-05-21 2023-07-18 Nextracker Llc Radial cam helix with 0 degree stow for solar tracker

Also Published As

Publication number Publication date
CA2332874C (fr) 2006-01-24
EP1077837A4 (fr) 2004-07-07
WO1999061287A1 (fr) 1999-12-02
CA2332874A1 (fr) 1999-12-02
EP1077837A1 (fr) 2001-02-28
AU4091099A (en) 1999-12-13

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